Reactor with jet impingment heat transfer

ABSTRACT

A catalytic reactor containing a core structure near the reactor axis and a casing structure near the reactor wall, the two structures differing from each other to promote catalysis and heat transfer, respectively. The casing contains a multiplicity of first devices for directing fluid centrifugally to impinge a reactor wall and second devices for permitting fluid to flow away from a reactor wall as the fluid flows from the inlet to the outlet of the reactor.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of International ApplicationPCT/US2005/042425 filed Nov. 22, 2005, which claims the benefit of thefiling date of U.S. provisional patent application Ser. No. 60/630,492,filed Nov. 23, 2004, the entire contents of each of which isincorporated herein by reference.

FIELD OF INVENTION

The present invention relates to catalytic reactors.

BACKGROUND INFORMATION

Catalytic reactors are known for promoting chemical reactions.Heterogeneous catalytic reactors are referred to herein.

Jet impingement of a fluid onto a solid surface is known to increase theheat transfer coefficient near the surface for applications such ascooling turbine veins and electronic components. U.S. Pat. No.5,029,638, the entire disclosure of which is incorporated herein byreference in its entirety, teaches jet impingement and suitableconfigurations to assist heat transfer in a compact heat exchanger.

U.S. Pat. Nos. 5,350,566, 5,651,946 and 4,719,090, referred tocollectively herein as the three patents, and each of which isincorporated herein by reference in its entirety, each teach permeable,engineered structures which may be used for catalysis and which providemixing of process fluid by enhancing turbulence throughout a reactor.The three patents each utilize corrugated sheets with the corrugationsinclined at an oblique angle to the general direction of fluid flow fromrespective reactor inlets to their outlets. The corrugated sheets areperforated or have spaces between them or both. The obliquely inclinedcorrugations induce a lateral component to the fluid velocity. Theperforations or spaces between the corrugated sheets provide lateralreturn paths for the fluid to maintain zero net lateral flow through thereactors. Lateral flows are induced at smaller scale distances while atlarger scale distances net lateral flow is balanced. Each of the threepatents teaches promoting mixing. The designs accordingly do notpreserve lateral momentum, but combine fluids with opposite lateralcomponent velocities, effecting mutual annihilation of their respectivelateral momentums. Such designs, while effective for mixing, are lesseffective for the destruction of a boundary layer at a reactor wall orfor increasing the heat transfer coefficient near the reactor wall thanthe projection of jets to impinge reactor walls at a low angle ofincidence.

Further, the three patents utilize parallel stacks of corrugated sheetsat alternating inclinations. Because the sheets are in flat, parallelplanes, the channels are chordal to the reactor cross section. Thisresults in some channels being normal to the reactor wall near someparts of the reactor wall and being parallel to the reactor wall nearother parts of the reactor wall, making them less effective and lessconsistent in increasing heat transfer at all parts of the reactor wallthan radially arrayed channels.

European Patent No. EP0025308 A1, the entire disclosure of which isincorporated herein by reference in its entirety, teaches an apparatusto cause fluid to flow alternatingly through a reactor core structureand through a space between the core structure and the vessel wall. Thispatent does not teach the destruction of the boundary layer at thereactor wall by jet impingement. All embodiments teach extensive fluidflow parallel to the reactor wall through an empty space between thereactor wall and the packing. The patent also teaches two alternativetypes of structure. One uses a perforated structure and the other usesan unperforated or solid structure. Where perforated structures areused, fluid flow is largely axial with turbulence and mixing intransverse directions and flow near the reactor wall is parallel to thatwall in the axial direction. Such flow is ineffective for destroying afluid boundary layer at a reactor wall relative to jet impingement.Where solid sheets are used, the open or effective cross sectional areaof the reactor is compromised because the flow passages within thecentral structure communicate with each other only via the empty spacebetween the core structure and the reactor wall. This constraintamplifies pressure drops relative to a suitably perforated structure orone in which crisscrossing channels generally communicate with eachother.

Use of truncated cones in EP0025308 A1 is anticipated exclusively forannular reactor cross sections. Such truncated cones are eitherperforated or placed in alternating zones in series to cause alternatingcentrifugal and centripetal flow along the reactor length. Fluid flowpaths extensively parallel to the reactor wall are described in detailfor all embodiments. The use of an empty space between the corestructure and the reactor wall promotes axial flow along the surface ofthe reactor wall instead of extensive, uniformly and finely distributedjet impingement of the reactor wall.

U.S. Pat. No. 4,985,230, the disclosure of which is incorporated hereinby reference in its entirety, teaches the transmission of heat from afirst wall to a second wall via fluid passing through channels thatalternately project the fluid toward a first and second wall. The wallsare parallel to and uniformly spaced from each other. The channelssupport a catalyst for performing heterogeneous catalysis of the fluid.One wall is a reactor wall and the other wall is an internal wall withinthe reactor. This art may be beneficial for the particular applicationof annular or bayonet reactors such as are used in steam reforming, butcan not be applied to a cylindrical or other solid shaped reactor. Theradially aligned channels in U.S. Pat. No. 4,985,230 are bounded in theaxial directions and must be fed by laterally flowing fluid. Because thechannels converge at the reactor axis they necessarily have reducedwidth or cross sectional area nearer the reactor axis than near thereactor wall. If such a packing were used throughout a cylindricalreactor the reduced cross sectional area of the converging walls nearthe reactor axis would restrict flow of fluid through channels, makingheat transfer ineffective. Extension of the channels to the reactor-axiswould also substantially increase undesirable pressure drop through thereactor.

SUMMARY OF THE INVENTION

The present invention relates to catalytic reactors of circular or otherfull cross section as opposed to annular spaces or reactor volumes thatat least partly contain or surround volumes not part of the reactor. Itis the purpose of the present invention to overcome each of the abovedifficulties and in particular to provide effective heat transferthroughout the volume and particularly near the reactor wall of acatalytic reactor of circular or other full cross section.

The present invention is useful for steam reforming reactors and forcatalytic converters for treatment to eliminate emissions from internalcombustion engines. In the latter case the present invention aidscooling of the converter to prolong the life of the catalyst.

The Summary of the Invention is provided as a guide to understanding theinvention. It does not necessarily describe the most generic embodimentof the invention or all species of the invention disclosed herein.

The present invention is an apparatus which carries out reactions offluid at a catalytic surface and which carries out heat transfer at areactor wall. A first structure near the axis of the reactor and asecond structure near the wall of the reactor are provided whichstructures differ from each other to promote the respective purposes ofcatalysis and heat transfer.

The catalytic reactor includes a volume that does not enclose a secondvolume, which second volume is not part of the reactor. Generally, thereactor is a cylindrical volume enclosed by a reactor wall with an inletat a first end and an outlet at a second end. The reactor contains solidsurfaces which contain a suitable active catalytic component to promotea desired reaction.

The structure near the axis of the reactor, herein referred to as thecore, extends from the reactor axis to a predetermined distance from theinside of the reactor wall toward the reactor axis. The predetermineddistance is about 0.01 to 0.4 and preferably 0.05 to 0.2 times thedistance from inside of the reactor wall to the reactor's axis. Thegeometric shapes comprising the core permit fluid flow in both axial andradial directions through communicating passages. Examples of suitablecores include spherical or cylindrical particles, pellets containingholes, Raschig rings, saddles, monolithic structures containingperforated channels or crisscrossing channels that communicate with eachother, and the like. Monolithic core structures, also referred to asengineered packings, are preferred, including those which can be foundin FIGS. 17 and 18 of U.S. patent application Ser. No. 10/886,237 filedJul. 7, 2004 entitled “Reactor with Primary and Secondary Channels” byJonathan J. Feinstein, the entire disclosure of which is incorporatedherein by reference. Monolithic cores may be composed of metal, ceramicor combinations of metal and ceramic, and are preferably composed of ametal substrate coated with a suitable catalyst carrier and activecatalyst.

The structure near the reactor wall, herein referred to as the casing,extends from the inside of the reactor wall to the predetermineddistance from the inside of the reactor wall. The casing is between thecore and the reactor wall at all parts of the reactor wall whereeffective heat transfer is desired. The casing contains a multiplicityof first devices for directing fluid centrifugally to impinge a reactorwall and second devices for permitting fluid to flow away from a reactorwall as the fluid flows from the inlet to the outlet of the reactor. Thefirst device is preferably a channel enclosed by solid walls. The seconddevice may be a wall, vane, channel or porous structure. An exampleporous structure is perforated walls or channels which permit fluid totraverse the walls or channels. The casing may be formed separately fromthe core or may be an extension of the core structure with suitablealteration of its porosity as to provide the first and second devices.An example alteration is for surfaces to be solid in the casing atsuitable locations, which analogous surfaces in the core are perforated.The casing may be composed of metal or ceramic and is preferablycomposed of a metal substrate coated with a suitable catalyst carrierand active catalyst.

The casing is a monolith, defined herein as an engineered structureincluding adjoining solid or perforated walls or sheets with fluidpassages between them. The structure of the core differs from thestructure of the casing in at least one of four ways. The firstdifference is that the core is not a monolith. The second difference isthat the core is a monolith that contains at least a 10% lowerpercentage volume of solid walled channels for directing fluidcentrifugally as it flows from the inlet to the outlet of the reactorthan the casing. The third difference is that the core is a monoliththat contains at least a 10% lower void volume than the casing. Theforth difference is that the core is a monolith that contains solidwalled channels for directing fluid centrifugally as it flows from theinlet to the outlet of the reactor which channels have at least a 10%higher average hydraulic diameter than the casing, where the hydraulicdiameter is equal to 4 times the cross sectional area of a channeldivided by the perimeter of the channel cross section.

Solid walled channels in the casing for directing fluid centrifugally asit flows from the inlet to the outlet of the reactor are radiallyarrayed and cause fluid to impinge the reactor wall and at an angle ofincidence of 0 to 85 degrees and preferably 0 to 45 degrees.

The permeability of the casing can be designed to be higher than thepermeability of the core such that the axial mass flux of fluid throughthe casing is higher than in the core to further increase the heattransfer coefficient of the fluid at the reactor wall.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A is a partial perspective cutaway view of one embodiment of areactor according to the present invention including a monolith ofsmooth and corrugated frustoconical sheets which have altered propertiesto provide different core and casing structures and functions.

FIG. 1B is a cross sectional view through a circumferential surface ofsome channels of the embodiment of FIG. 1A.

FIG. 1C is a cross sectional view through a circumferential surface of asecond variation of channel shapes of the embodiment of FIG. 1A.

FIG. 1D is part of a transverse cross section of the reactor of theembodiment of FIG. 1A, illustrating the communication of channels withinthe casing and the radial fluid flow patterns.

FIG. 2A shows a partial perspective view of a second embodiment of acasing of the present invention.

FIG. 2B illustrates a method for forming the embodiment illustrated inFIG. 2A.

FIG. 3A is a longitudinal section view of another embodiment of thepresent invention.

FIG. 3B illustrates details of the casing shown in FIG. 3A.

DETAILED DESCRIPTION OF THE INVENTION

The Detailed Description is exemplary and not limiting.

Referring to FIG. 1A unless otherwise indicated, FIG. 1A illustrates apartial perspective cutaway view of an example embodiment. Catalyticreactor 100 has an inlet 101, an outlet 102, and cylindrical reactorwall 103. The internal volume includes a core 110 and a casing 120. Thecore comprises a monolithic substrate composed of smooth cone shapedsheets 111, shown in both the transverse and longitudinal sections,separated by corrugated cone shaped sheets 112, shown only in thetransverse cross section. Both the smooth and corrugated sheets in thecore are perforated as denoted in this and other examples of perforatedsurfaces by dashed lines. The spaces between the smooth and corrugatedsheets constitute channels 113. The smooth and corrugated cones arepreferably at an angle of 45° to the reactor wall. Channels 113 areradially arrayed. Fluid passes from the inlet to the outlet through thecore along channels 113 and through perforations in the channels withminimal tortuousity in the axial direction. The core contains no solidwalled channels for directing fluid centrifugally as it flows from theinlet to the outlet of the reactor.

The casing constitutes an extension of the smooth and corrugated conesin the core, but with alteration of the core structure to promote heattransfer at the reactor wall. The casing includes smooth frustoconicalsheets 121 interleaved with and separated by corrugated frustoconicalsheets 122, which are extensions of sheets 111 and 112, respectively.The spaces between the smooth and corrugated sheets in the casing createchannels 123, which extend in the axial direction along thefrustoconical surfaces. The frustoconical surfaces of the casing are atthe same angle of inclination to the reactor wall as the conicalsurfaces in the core. The smooth sheets 121 abut the reactor wall. Thereis a gap, not shown, between the corrugated sheets of the casing and thereactor wall. The gap is described in the description of FIG. 1D. Thesheets of the casing contain portions that are perforated 124 and otherportions that are solid 114, creating channels 115 that are completelyenclosed by solid surfaces and channels 125 that are at least partiallyenclosed by perforated surfaces. Solid channels 115 direct fluidcentrifugally to impinge the reactor wall as the fluid flows from theinlet to the outlet of the reactor. The said centrifugal flow isdepicted by arrow 116. Channels 125 permit fluid to return centripetallyfrom the reactor wall as the fluid flows from the inlet to the outlet ofthe reactor. Arrow 126 depicts the flow direction of fluid traversingperforated channels 125.

Channels 115 are arranged and aligned in axial stacks one channelabreast in the circumferential direction. Channels 125 are arranged andaligned in axial stacks at least two channels abreast in thecircumferential direction. The stacks of channels 115 and of channels125 extend from the inlet to the outlet of the reactor or over theportions of the reactor where effective heat transfer with theenvironment of the reactor is desired. Stacks of channels 115 and 125alternate around the entire circumference of the reactor wall or aroundthe parts of the reactor wall where effective heat transfer with thereactor's environment is desired. The arrangement of the stacks isfurther clarified in FIGS. 1B, 1C and 1D.

Although it is generally preferred that smooth and corrugated sheets inthe casing are perforated to provide uniform permeability, in someapplications where heat transfer is relatively more important thanpressure drop, the perforation density may be designed to provide loweraxial permeability nearer the reactor axis than near the reactor wall.The said variation of permeability promotes the relative flow andvelocity of fluid impinging the reactor wall for a given fluid flowthrough the reactor and further increases the heat transfer coefficientat the reactor wall.

Referring to FIG. 1B unless otherwise indicated, FIG. 1B illustrates acircumferential surface through the casing of the embodiment in FIG. 1A.The casing includes alternating smooth and corrugated frustoconicalsheets forming channels between them. Portions 114 of the smooth sheetsare solid as illustrated by solid lines, and portions 124 of the smoothsheets are perforated as illustrated by dashed lines. Portions 117 ofthe corrugated sheets are solid as illustrated by solid lines, andportions 127 of the corrugated sheets are perforated as illustrated bydashed lines. Channels 115 are enclosed by solid surfaces, and channels125 are at least partially enclosed by perforated surfaces. The portionsof the smooth and corrugated sheets are so arranged as to createvertical or axial stacks one channel abreast of channels 115 alternatingcircumferentially with vertical stacks of channels 125 three channelsabreast. The stacks extend from the inlet to the outlet of the reactoror where effective heat transfer is desired. Channels 115 direct fluidcentrifugally to impinge the reactor wall as they flow along the lengthof the said channels. Fluid in channels 125 substantially traverses thechannels 125 to effect flow both from the inlet to the outlet of thereactor and centripetally away from the reactor wall. Optional groves ordimples may be formed in the smooth and corrugated sheets to form tongueand groove junctions 130 to index the relative positions of the smoothand corrugated sheets and thereby assure alignment of the stacks. Thepercentage of open or perforated area of smooth sheets enclosingchannels 125 and the number of channels abreast in a given stack ofchannels 125 is adjusted to permit fluid to flow through the smoothperforated surfaces at sufficiently low pressure drop for fluid to flowthrough the casing to provide desired heat transfer at the reactor wall.The percentage of open or perforated area of surfaces 124 may be higherthan in the smooth sheets in the core, or the number of channels 124abreast in a given stack may be increased, according to the angle ofinclination of the cones and the cross section shape of thecorrugations.

Referring to FIG. 1C unless otherwise indicated, FIG. 1C illustrates acircumferential surface through the casing of a different corrugationprofile of the embodiment in FIG. 1A. The casing comprises alternatingsmooth and corrugated frustoconical sheets forming channels betweenthem. Portions 114 of the smooth sheets are solid as illustrated bysolid lines, and portions 124 of the smooth sheets are perforated asillustrated by dashed lines. Portions 117 of the corrugated sheets aresolid as illustrated by solid lines, and portions 127 of the corrugatedsheets are perforated as illustrated by dashed lines. Channels 115 areenclosed by solid surfaces, and channels 125 are at least partiallyenclosed by perforated surfaces. The portions of the smooth andcorrugated sheets are so arranged as to create vertical stacks onechannel abreast of channels 115 alternating circumferentially withvertical stacks of channels 125 three channels abreast. The stacksextend from the inlet to the outlet of the reactor or where effectiveheat transfer is desired. Channels 125 direct fluid centrifugally toimpinge the reactor wall as the fluid flows along the length of the saidchannels. Fluid in channels 125 substantially traverses the channels 125to effect flow both from the inlet to the outlet of the reactor andcentripetally away from the reactor wall. Optional groves or dimples maybe formed in the smooth and corrugated sheets to form tongue and groovejunctions 130 to index the relative positions of the smooth andcorrugated sheets and thereby assure alignment of the stacks.

The shape of the corrugations incorporates narrow concave downwardsections and wide concave upward sections. The shape of corrugation inFIG. 1C permits a more uniform width of stacks containing channels 115relative to the shape illustrated in FIG. 1B.

Referring to FIG. 1D unless otherwise indicated, FIG. 1D shows part of atransverse section through the reactor embodiment in FIG. 1A. Reactor100 has a wall 103, a core 110, and a casing 120. Structures within thecore are not shown. In the casing solid, corrugated sheets 117 separatestacks 118 of channels enclosed by solid corrugated, and smooth sheetsfrom stacks 128 of channels at least partially enclosed by perforatedsmooth and corrugated sheets. Alternating stacks 118 and 128 arepositioned around the circumference of the reactor wall. In stacks 118channels are stacked one channel abreast and are narrowercircumferentially than stacks 128, in which channels are stacked atleast two channels abreast circumferentially. Channels in stacks 118direct fluid centrifugally to impinge the reactor wall as depicted byarrows 116. Fluid directed to the reactor wall by channels in stacks 118exits stacks 118 and enters stacks 128 via a gap 131 between thecorrugated sheets and the reactor wall as depicted by arrows 132. Fluidentering stacks 128 near the reactor wall returns centripetally from thereactor wall as depicted by arrows 126.

The width of the gap is a multiple of the average circumferential widthof stacks 118 at their ends nearest to the reactor wall. In applicationswhere it is relatively more important to minimize pressure drop thanincrease heat transfer, the multiple may be in the range of about 0.5 to2.0. For applications where attainment of high heat transfer isrelatively more important than minimization of pressure drop themultiple may be in the range of about 0.1 to 0.7. The width of the gapmay be uniform or serrated, according to the way the edges of thecorrugated sheets are cut before forming. Where the gap is not uniformthe said multiples pertaining to the gap width define the average gapwidth.

Referring to FIG. 2A unless otherwise indicated, FIG. 2A illustratesanother embodiment of a casing according to the invention in whichchannels with solid walls are provided for conveying fluid both to andfrom a reactor wall. It is suitable for use in a cylindrical reactor.Alternating columns positioned between the core and reactor wall containvanes that direct centrifugal and centripetal flows of fluid,respectively. The reactor inlet, not shown, is above, and the reactoroutlet, not shown, is below the illustrated section of casing 200.Casing 200 comprises column separating walls 201 that separate columnsfrom each other. Columns 202 contain vanes 203 for directing fluidcentripetally away from a reactor wall, not shown, as the fluid flowsfrom the inlet to the outlet of a reactor, or from the top to the bottomof the casing as illustrated. The top edges of vanes 203 abut thereactor wall to separate the column separating walls from the reactorwall by a gap distance 204. Columns 205 contain vanes 206 and gapspacers 207 for directing fluid centrifugally to impinge a reactor wall.The lower edges of the gap spacers abut the reactor wall to separate thecolumn separating walls from the reactor wall by a gap distance 208,which is equal to gap distance 204. Column width spacers 209 near thereactor wall and column width spacers 210 abutting the core maintain thecircumferential width of columns 205 and 202, respectively. Widths ofcolumns 202 and 205 are about equal to each other. Column width spacers209 are wider than spacers 210 so that the casing conforms to thecurvature of the reactor wall. Raised dimples 211 may be pressed intothe column separating walls on either side of the vanes to hold thevanes in position. Arrows 212 indicate the direction of fluid flowthrough the casing of first approaching the reactor wall via columns 205between vanes 206, then impinging the reactor wall, not shown, thenturning laterally in the circumferential direction through gaps betweencolumn separating walls and the reactor wall, to enter columns 202 andbe redirected centripetally by vanes 203 away from the reactor wall asthey flow from the inlet to the outlet of the reactor. The casing liesbetween the core and the reactor wall around the entire reactorcircumference and from the inlet to the outlet of the reactor.

Referring to FIG. 2B unless otherwise indicated, FIG. 2B illustrates aforming method to construct a casing shown in FIG. 2A. The casing isconstructed from metal sheet 212. Vanes 203 and gap spacers 207 are cuton three edges as shown and are folded forward about 45 degrees alongdotted lines 213 and 217, respectively. Vanes 206 are cut on three edgesas shown and folded backward about 45 degrees along dotted lines 216.The sheet is folded forward along dotted lines 220 proximate the sidesof vanes 203 and is folded backwards along dotted lines 221 proximatethe sides of vanes 206 about 90 degrees or until column separating walls201 contact the edges of vanes 203 and 206. Column width spacers 209 and210 are preferably at the same elevation. The widths of vanes 203 and206 may be tapered and the width of column width spacers 209 may begreater than the width of column width spacers 210 to allow the casingto conform to the curvature of the reactor wall and for the vanes toabut all parts of the separating walls. The folded casing is then coatedwith a suitable catalyst carrier and active catalyst and is inserted ina reactor between a core and reactor wall.

Referring to FIG. 3A unless otherwise indicated, FIG. 3A illustrates alongitudinal cross section of an example embodiment of the presentinvention. Catalytic reactor 300 has an inlet 301, an outlet 302, andcylindrical reactor wall 303. The internal volume comprises a core 304and a casing 305. The core comprises a random packing of solid aluminaspheres which are impregnated with an active catalyst. The casing isbetween the core and the reactor wall at all parts of the reactor wallfrom the inlet to the outlet of the reactor. The casing comprises flatrings 306 and 307 separated by axial spaces. The surface between thecasing and the core may optionally comprise a perforated wall depictedby dashed lines 308. The direction of fluid flow into the inlet throughthe reactor and out of the outlet is shown by arrows 309.

Referring to FIG. 3B unless otherwise indicated, FIG. 3B illustrates anenlarged portion near the reactor wall of the view described in FIG. 3A.The casing 305 abuts the reactor wall 303. The casing comprises innerflat rings 306 and outer flat rings 307. The inner rings and outer ringsare positioned relative to each other and the wall as to form baffles oralternating channels for directing fluid to flow centrifugally toimpinge a reactor wall as depicted by arrow 310 and return centripetallyfrom a reactor wall as depicted by arrow 311 as the fluid flows from theinlet to the outlet of the reactor. Fluid flowing through channelscentrifugally impinges the reactor wall as depicted by arrow 312 and isdeflected to channels in which it flows centripetally. Fluid passages inthe casing communicate with fluid passages in the core. An optionalperforated wall may be positioned between the casing and core asdepicted by dashed line 308. Outer flat rings abut the reactor wall andhave an inner diameter smaller than the outer diameter of the inner flatrings. Inner flat rings abut the core at their inside diameter, whichdefines the inside diameter of the casing and have an outer diameter atleast half the distance from the core to the reactor wall. The inner andouter rings are positioned in an alternating sequence from the inlet tothe outlet of the reactor. The spacing between adjacent inner and outerrings is uniform. The gap between the inner rings and the reactor wallis approximately the same distance as the axial distance between anadjacent inner and outer ring. The distance from the core to the reactorwall is about 0.01 to 0.4 and preferably 00.05 to 0.2 times the distancefrom inside of the reactor wall to the reactor's axis. The inner andouter rings are secured by longitudinal supports or struts, not shown.

EXAMPLE

As an example of the embodiment using a casing as described in FIG. 2B,the following dimensions may be used. Numbered references to parts ofthe casing refer to those parts as numbered in FIG. 2B. The examplepertains to a steam reforming reactor used in the manufacture ofhydrogen having a wall with an inside diameter of 100 mm, a thickness of13 mm, a length of 10 meters, an inlet at the top end and an outlet atthe bottom end. The core diameter is 80 mm. The casing extends from thecore to the reactor wall, a distance of 10 mm. The casing is dividedinto 80 columns, which are approximately 3.9 mm wide at the reactorwall. A metal sheet 0.2 mm thick, 945 mm wide and 500 mm long in thereactor's axial direction is used for the casing substrate. Columnseparating walls are 8.0 mm wide, leaving a 2.0 mm gap between thecolumn separating walls and the reactor wall. Vanes 203 are 14.1 mmlong, 3.9 mm wide at the cut end and 3.5 mm wide at the folded end.Vanes 206 are 11.4 mm long, 3.5 mm wide at the cut and 3.9 mm wide atthe folded end. Gap spacers 207 are 2.8 mm long and 3.9 mm wide. Columnwidth spacers 209 are 3 mm high and 3.9 mm wide. Column width spacers210 are 3 mm high and 3.5 mm wide. Spacers 209 and 210 are preferablyaligned with respect to elevation. Vanes 203 and gap spacers 207 arefolded forward 45 degrees along fold lines 213 and 217, respectively,and vanes 206 are folded backwards 45 degrees along fold lines 216. Thesheet is folded forward about 90 degrees along fold lines 220, which are3.5 mm apart and proximate the sides of vanes 203. The sheet is foldedbackwards about 90 degrees along fold lines 221, which are 3.9 mm apartand proximate the sides of vanes 206. The casing is formed into atubular shape and the first and last column separating walls may becaused to interlock by folding them.

The core is constructed as described in Example 1 of U.S. patentapplication Ser. No. 10/886,237 filed Jul. 7, 2004 entitled “Reactorwith Primary and Secondary Channels” by Jonathan J. Feinstein,constructed to an 80 mm diameter and in 500 mm long, nested modules.

The core and casing are coated with a conventional catalyst carriercontaining alumina and impregnated with a suitable active catalystcontaining nickel oxide. Several such casing assemblies and coreassemblies are mounted in the reactor end to end to fill the reactor.Process gases are made to flow through the reactor to perform steamreforming.

1. A catalytic reactor comprising: an inlet, an outlet, a reactor axis,a reactor wall being disposed about the reactor axis, a core structuredisposed at least proximate the reactor axis and having a plurality ofpassages for passage of fluid therethrough, a monolithic casingstructure disposed between the core structure and the reactor wall, themonolithic casing structure being distinct from the core structure andincluding a plurality of channels in fluid communication with theplurality of passages of the core structure, for directing fluid throughthe reactor centrifugally to impinge said reactor wall at an angle ofincidence not more than 85° with respect to the reactor wall.
 2. Thereactor of claim 1, wherein the core structure is non-monolithic.
 3. Thereactor of claim 1, wherein the core structure has a void fraction whichis at least 10% lower than a void fraction of the monolithic casingstructure.
 4. The reactor of claim 1, wherein the plurality of passagesin the core structure have a hydraulic diameter, and the plurality ofchannels in the monolithic casing structure have a hydraulic diameter,and the average hydraulic diameter of the core structure is at least 10%greater than the average hydraulic diameter of the monolithic casingstructure.
 5. The reactor of claim 1, wherein each of the plurality ofchannels in the monolithic casing structure and each of the plurality ofpassages in the core structure have respective percentage volumes fordirecting fluid centrifugally as it flows from the inlet to the outletof the catalytic reactor, and the core structure has at least a 10%lower percentage volume for directing fluid centrifugally as it flowsfrom the inlet to the outlet of the reactor than that of the monolithiccasing structure.
 6. The reactor of claim 1, wherein the monolithiccasing structure and the core structure have respective permeabilities,and wherein the permeability of the monolithic casing structure isgreater than the permeability of the core structure such that axial massflux of fluid through the monolithic casing structure is greater thanaxial mass flux of fluid through the core structure.
 7. The reactor ofclaim 1, wherein the plurality of passages of the core structure isdefined by only perforated walls.
 8. The reactor of claim 1, wherein theplurality of channels of the casing structure are radially arrayed. 9.The reactor of claim 1 wherein the monolithic casing structure and thecore structure have a plurality of surfaces, and wherein at least someof the surfaces of at least one of the monolithic casing structure andthe core structure comprise a catalyst.
 10. The reactor of claim 1wherein at least one of the monolithic casing structure and the corestructure comprises at least one of a metal or ceramic substrate. 11.The reactor of claim 10 wherein the metal is perforated sheet metal. 12.The reactor of claim 1 wherein the core structure extends from thereactor wall to about 0.01 to 0.4 of a distance from the reactor wall tothe reactor axis.
 13. The reactor of claim 1 wherein the monolithiccasing structure comprises first and second columns, which each includedevices, to direct a fluid flowing therethrough centrifugally andcentripetally, respectively.
 14. The reactor of claim 13 wherein thefirst and second columns are separated by walls, and wherein the firstand second columns are in fluid communication proximate the reactorwall.
 15. The reactor of claim 1 wherein the catalytic reactor isemployed for at least one of steam reforming and for the after treatmentof emissions from an internal combustion engine. 16-26. (canceled) 27.The reactor of claim 1 wherein the casing structure has a geometricconfiguration, and wherein the geometric configuration of the casingstructure is distinct from an extension of the geometric configurationof the core structure from the reactor axis to the reactor wall.
 28. Amethod of forming a reactor containing a monolithic structure withradially arrayed channels for directing fluid flowing therethroughcentrifugally and centripetally, respectively, comprising bending asheet to form a series of radially and axially aligned walls joined bycircumferentially and axially aligned walls which circumferential wallsbetween consecutive pairs of radially aligned walls are alternatinglymore proximate a reactor wall and more remote from a reactor wall, thecircumferential walls further having portions bent from their generalalignment to oblique angles to the reactor axis to direct fluidcentrifugally or centripetally as the fluid flows through the reactor,the said structure being placed proximate a reactor wall.
 29. Amonolithic structure for use in a reactor comprising radially arrayedchannels for directing fluid flowing therethrough centrifugally andcentripetally, respectively, a plurality of radially and axially alignedwalls joined by circumferentially and axially aligned walls, whichcircumferential walls between consecutive pairs of radially alignedwalls are alternatingly more proximate a reactor wall and more remotefrom a reactor wall, the circumferential walls further having portionsinclined at an oblique angle to the reactor axis to direct fluidcentrifugally or centripetally as the fluid flows through the reactor,the monolithic structure being disposed proximate a reactor wall. 30.The reactor of claim 1, wherein the plurality of channels of themonolithic casing structure are defined by non-perforated channel walls.31. An engineered packing for use in a reactor comprising: an inlet, anoutlet, an axis, a core structure disposed at least proximate the axisand having a plurality of passages for passage of fluid therethrough,and a monolithic casing structure disposed about at least a portion ofthe core structure, the monolithic casing structure being distinct fromthe core structure and including a plurality of channels in fluidcommunication with the plurality of passages of the core structure. 32.The engineered packing of claim 31, wherein the core structure isnon-monolithic.
 33. The engineered packing of claim 31, wherein the corestructure has a void fraction which is at least 10% lower than a voidfraction of the monolithic casing structure.
 34. The engineered packingof claim 31, wherein. the plurality of passages in the core structurehave a hydraulic diameter, and the plurality of channels in themonolithic casing structure have a hydraulic diameter, and the averagehydraulic. diameter of the core structure is at least 10% greater thanthe average hydraulic diameter of the monolithic casing structure. 35.The engineered packing of claim 31, wherein each of the plurality ofchannels in the monolithic casing structure and each of the plurality ofpassages in the core structure have respective percentage volumes fordirecting fluid centrifugally as the fluid flows from the inlet to theoutlet of the engineered packing, and the core structure has at least a10% lower percentage volume for directing fluid centrifugally as itflows from the inlet to the outlet of the engineered packing than thatof the monolithic casing structure.
 36. The engineered packing of claim31, wherein the monolithic casing structure and the core structure haverespective permeabilities, and wherein the permeability of themonolithic casing structure is greater than the permeability of the corestructure such that axial mass flux of fluid through the monolithiccasing structure is greater than axial mass flux of fluid through thecore structure.
 37. The engineered packing of claim 31, wherein theplurality of passages of the core structure is defined by onlyperforated walls.
 38. The engineered packing of claim 31, wherein theplurality of channels of the casing structure are radially arrayed. 39.The engineered packing of claim 31, wherein the monolithic casingstructure and the core structure have a plurality of surfaces, andwherein at least some of the surfaces of at least one of the monolithiccasing structure and the core structure comprise a catalyst.
 40. Theengineered packing of claim 31, wherein at least one of the monolithiccasing structure and the core structure comprises at least one of ametal or ceramic substrate.
 41. The engineered packing of claim 40,wherein the metal is perforated sheet metal.
 42. The engineered packingof claim 31, wherein the monolithic casing structure comprises first andsecond columns, which each include devices, to direct a fluid flowingtherethrough centrifugally and centripetally, respectively.
 43. Theengineered packing of claim 42, wherein the first and second columns areseparated by walls, and wherein the first and second columns are influid communication proximate the reactor wall.
 44. The engineeredpacking of claim 31, wherein the catalytic reactor is employed for atleast one of steam reforming and for the after treatment of emissionsfrom an internal combustion engine.
 45. The engineered packing of claim31, wherein the casing structure has a geometric configuration, andwherein the geometric configuration of the casing structure is distinctfrom an extension of the geometric configuration of the core structure.46. The engineered packing of claim 31, wherein the plurality ofchannels are defined by non-perforated walls.
 47. A method of forming anengineered packing for use in a reactor having radially arrayed channelsfor directing fluid flowing therethrough centrifugally andcentripetally, respectively, comprising bending a sheet to form a seriesof radially and axially aligned walls joined by circumferentially andaxially aligned walls which circumferential walls between consecutivepairs of radially aligned walls are alternatingly more proximate areactor wall and more remote from a reactor wall, the circumferentialwalls further having portions bent from their general alignment tooblique angles to an axis of the engineered packing to direct fluidcentrifugally or centripetally as the fluid flows through the engineeredpacking.
 48. An engineered packing for use in a reactor comprisingradially arrayed channels for directing fluid flowing therethroughcentrifugally and centripetally, respectively, a plurality of radiallyand axially aligned walls joined by circumferentially and axiallyaligned walls, which circumferential walls between consecutive pairs ofradially aligned walls are alternatingly more proximate a wall of thereactor and more remote from the wall of the reactor, thecircumferential walls further having portions inclined at an obliqueangle to the reactor axis to direct fluid centrifugally or centripetallyas the fluid flows through the reactor, the engineered packing beingdisposed proximate the wall of the reactor.